Brassiere cup plastic strip support and manufacturing method therefor

ABSTRACT

A brassiere cup support and method of manufacturing the support and cup therewith. The support comprises a plastic support in the shape of one or more of an underwire, an uplifting panel, a reinforcing pad, a sternum region, or an extended fish bone like pattern capable of providing desired “firmness” or “hardness” along its length and thereby providing desired degrees of support therealong. The plastic support comprises at least one layer of polymer and at least one layer of a second material, wherein the at least one layer of polymer and the at least one layer of the second material are in the form of a sandwich. 
     Preferably, the plastic support comprises at least two layers of polymer and at least one layer of the second material, with an adhesive applied therebetween to secure the layers to one another.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of pending U.S. non-provisional patent application Ser. No. 13/244,577 filed Sep. 25, 2011, which claims benefit of Hong Kong Patent Application Serial Number HK11105043.3, filed on May 23, 2011 and Hong Kong Patent Application Serial Number HK11105044.2 filed on May 23, 2011. This continuation-in-part application also claims priority under 35 U.S.C. §119 to United Kingdom patent application GB1309939.5, filed Jun. 4, 2013. Each of the aforementioned related patent applications is herein incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates to brassieres. The invention more particularly, although not exclusively, relates to a brassiere having a specially formed plastic support and a method of manufacturing a cup for such a brassiere using the specially formed plastic support.

Known brassieres have a stiff metallic underwire sewn into the bottom of each cup. Such underwires may provide an adequate level of support but are uncomfortable, unsightly and can protrude from the brassiere after a time of use. Such metallic underwires are also of constant cross-section and stiffness throughout their length and therefore do not provide a desired level of variable support throughout their length.

OBJECTS OF THE INVENTION

It is an object of the present invention to overcome or substantially ameliorate the above disadvantages and/or more generally to provide an improved brassiere and brassiere cup plastic support and method of manufacture therefor.

DISCLOSURE OF THE INVENTION

There is disclosed herein a brassiere cup plastic support. The plastic support may be in the shape of one or more of an underwire, an uplifting panel, a reinforcing pad, a sternum region, or an extended fish bone like pattern. Such plastic support is capable of providing desired “firmness” or “hardness” along its length and thereby providing desired degrees of support therealong.

Preferably, the plastic support comprises at least one layer of polymer.

The plastic support may further comprise at least one layer of a second material, wherein the at least one layer of polymer and the at least one layer of the second material are in the form of sandwich.

Preferably, the plastic support comprises at least two layers of said polymer and the at least one layer of the second material is formed sandwiched between said at least two layers of said polymer.

Preferably, the second material is selected from a group of polymer, fabric and foam.

It is preferred that the plastic support has a constant number of layers of the polymer and second material, so as to have a uniform crosswise dimension along its length.

Alternatively, the plastic support may have a variable number of layers of at least one of the polymer and second material along its length, so as to have a varied crosswise dimension along its length.

Preferably, the dimension graduates from a minimum at one end of the plastic support to a maximum at the other end of the plastic support.

Preferably, the polymer is ethylene vinyl acetate.

Preferably, the polymer is resin.

Preferably, the plastic support is formed by layers of polymer and second material adhered to each other in the form of a sandwich.

Preferably, the plastic support is initially formed by cutting a desired shape from the plastic support.

There is further disclosed herein a brassiere cup having the above-disclosed plastic support located in an edge region and/or an outer region thereof.

Preferably, the plastic support is located between layers of material from which the cup is formed, and even furthermore, the plastic support is molded in place with formation of the cup.

There is further disclosed herein a brassiere having a pair of the above-disclosed brassiere cups.

Furthermore, there is disclosed herein a method of manufacturing a brassiere part with a plastic support, comprising the steps of:

-   -   (a) providing at least one layer of a polymer;     -   (b) providing at least one layer of a second material on top of         the layer of polymer;     -   (c) applying an adhesive at the interface between the at least         one layer of polymer and the at least one layer of the second         material, for causing said layers to adhere to each other and         form a layered plastic support;     -   (d) cutting the plastic support from the layered plastic         support, where the size and shape of the plastic support         corresponds to a desired size and shape for the plastic support         of the brassiere part;     -   (e) providing a mold for forming the brassiere part with a         trough;     -   (f) laying down in the mold a brassiere part material from which         the brassiere part is to be formed, such that some of the         brassiere part material extends into the trough;     -   (g) positioning the plastic support upon the brassiere part         material that extends into the trough; and     -   (h) applying heat to the mold sufficient to soften the plastic         support so that it consolidates into a desired shape as defined         by the shape of the trough, melts into a continuous support and         forms a whole piece of material together with the brassiere part         material.

Preferably, in some embodiments, the second material may be selected from a group of foam, fabric and polymer.

Preferably, in some embodiments, the brassiere part is a cup and the plastic support is an underwire, wherein the plastic material consolidates in the trough to form the underwire of variable or uniform width and/or depth from one end of the underwire to the other.

Optionally, the methods disclosed above may further comprise providing additional layers of polymer as well as additional layers of second material sandwiched therebetween.

Even furthermore, further layers of material from which the brassiere cup is to be formed can be laid down so as to cover the plastic material in the trough before the step of applying heat.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred forms of the present invention will now be described by way of example with reference to the accompanying drawings, wherein:

FIG. 1 is a schematic perspective illustration of a brassiere in accordance with one embodiment;

FIG. 2 is a schematic elevation of a plastic support in accordance with one embodiment;

FIG. 3 is a schematic cross-sectional end elevation of a thick end portion of the plastic support of FIG. 2;

FIG. 4 is a schematic cross-sectional end elevation of a thin end portion of the plastic support of FIG. 2;

FIG. 5 is a schematic cross-sectional elevation of a prior art underwire;

FIG. 6 is a schematic elevation of the prior art underwire of FIG. 5;

FIG. 7 is a schematic cross-sectional elevation of the plastic support of FIG. 2;

FIG. 8 is a schematic elevation of the plastic support of FIG. 7;

FIG. 9A is a cross-sectional view of the non-uniform material of which a plastic support is made in accordance with one embodiment of the invention;

FIG. 9B is a cross-sectional view of the uniform material of which a plastic support is made in accordance with another embodiment of the invention;

FIG. 10 is a schematic perspective illustration of a mold used to form a brassiere cup with an underwire of variable depth along its length;

FIG. 11 is a schematic perspective illustration of a mold used to form a brassiere cup with an underwire of variable width along its length;

FIG. 12 is a schematic perspective illustration of a brassiere with plastic support in another embodiment of the present invention;

FIG. 13 is a schematic elevation of a plastic support in the form of fish bone pattern of FIG. 12;

FIG. 14 is a schematic cross-sectional elevation of the plastic support of FIG. 12;

FIG. 15 is a schematic elevation of the plastic support in the form of fish bone pattern of FIG. 12; and

FIG. 16 is a schematic elevation of a mold used to form a brassiere cup with the plastic support in the form of fish bone pattern of variable depth and/or width along its length of FIG. 12.

DESCRIPTION OF THE PREFERRED EMBODIMENT

In FIG. 1 of the accompanying drawings there is depicted schematically a brassiere 10 having a pair of breast cups, a pair of shoulder straps, a front band, a pair of underwires 11, and a back strap which is an extension of the front band. The back strap is connected by hook and loop fasteners 40. The brassiere also includes a pair of uplifting panels 42 and a reinforced central sternum area 17 between the cups.

A plastic support in a form of underwire 11 is shown in FIGS. 2 to 4. Underwire 11 comprises a plastic support. The plastic support has at least one layer of polymer either alone or together with at least one layer of foam and/or fabric. Use of foam or fabric is a matter of choice subject to application. Optionally, the plastic support may vary in thickness from a maximum as shown at A at one end of the underwire to a minimum as shown at B at the other end of the underwire. As noted above, alternatively, the underwire can be of variable width along its length.

In this embodiment, the at least one layer of polymer 12 is placed between layers of foam 14 as shown in FIGS. 7 and 8.

The variation of the thickness (or width) of the plastic support is a matter of choice subject to the support desired. In this illustration, the thickness of the plastic support in a form of underwire 11 varies gradually between A and B. Underwire 11 is surrounded by foam 13 as shown in FIGS. 3 and 4. The foam 13 and underwire 11 are typically molded into the bottom edge region of the brassiere cup during the manufacturing process. As an alternative, the underwire 11 could be positioned and held in place with respect to the brassiere cup for subsequent lamination of the underwire 11 into the brassiere cup itself.

One end of the underwire 11 (typically the end closest to the wearer's shoulder) is the thickest, whereas the other end of the underwire 11 (typically the end nearest the wearer's sternum) is the thinnest. This provides a gradual reduction in stiffness of the underwire 11 along its length. In order to finely tune the degree of support and comfort along the length of the underwire 11, differing materials and material thicknesses may be adopted. Indeed different configurations might be required for different cup sizes to suit the anatomy of different women.

FIGS. 5 and 6 are included for comparison and show a typical prior art underwire structure. In the prior art, the underwire includes a central metallic wire 11B surrounded by a metallic wire loop 11A. These two parts are encased in foam 13. Although the foam 13 provides some degree of protection from the hard metallic core, the stiffness of the wire results in discomfort.

FIGS. 7 and 8 on the other hand show a plastic support in the form of underwire 11 made in accordance with the present invention and in which the underwire 11 is also surrounded by foam 13. As shown in FIG. 8, the thickness or depth of the underwire 11 diminishes gradually from one end to the other. In this case the dimension A is greater than B.

FIG. 7 shows underwire 11 having a plastic support which has a layer of polymer 12 between layers of foam 14 and varies in thickness from a maximum as shown at A at one end of the underwire 11 to a minimum as shown at B at the other end of the underwire 11.

The underwire 11 is typically formed in and located at a transition position between the cup and the front band of the brassiere. The underwire 11 would be orientated with its flatter side facing the body of the wearer so that the convex side of the underwire 11 faces outwardly away from the body. The brassiere cup might be formed as a lamination of foam plastics material between layers of which the underwire 11 is located.

In another embodiment, underwire 11 may be of constant uniform thickness throughout its length. The thickness of the underwire depends on the number of layers of polymer and the number of layers of foam and/or fabric used.

FIG. 9A shows a plastic material 20, in accordance with one aspect of the present invention, from which a plastic support can be cut-out or otherwise manufactured from. Plastic material 20 is made so as to comprise one or more layers of polymer 12 and one or more layers of a second material 14 positioned in the form of sandwich with polymer 12. The number of layers of polymer 12 and the number of layers of the second material 14 may vary along the length of the plastic material 20, depending on the final shape and thickness of the desired plastic support. In a manner similar to what was described in the prior embodiments, the thickness (and/or width) of polymer 12 and the second material 14 may also vary. The embodiment of FIG. 9A shows one end of the material 20 is thicker than the other end by having an additional layer of polymer 12 and second material 14. A plastic support of a desired shape and thickness may then be cut from the material 20 shown. The plastic support can be in a shape of an underwire 11, a reinforcing pad 40, an uplifting panel 42, or a sternum region 17, as shown in FIG. 1. Additionally or optionally, the plastic support can be in a different shape of an uplifting panel 144, a reinforcing pad 140, a sternum region 142, or an extended fish bone like pattern 130 as shown in FIG. 12. It is noted that the desired shape cut from material 20 may correspond differently to the final/desired size and shape for the plastic support, since its final shape may change somewhat during the molding process of the plastic support with the rest of the brassiere cup, which molding process is described in conjunction with FIG. 10 and FIG. 11. The extended fish bone like pattern 130 is further illustrated in FIGS. 13, 14, 15 and 16. The thickness, width and length of each of the bones 111 of the extended fish bone like pattern 130 may vary according to the desired shape. The main body 121 of the extended fish bone like pattern 130 may also have different thickness and width along its length. As shown in FIGS. 13, 15 and 16, width A and B of the main body 121 are of different values. Similarly, thickness X and Y of the main body 121 are of different values as shown in FIG. 14.

FIG. 9B shows a plastic material 20 of which the plastic support of the present invention is made in accordance with another embodiment of the invention. In this embodiment, material 20 also comprises layers of polymer 12 and layers of a second material 14 in the form of sandwich. However, unlike those shown in FIG. 9A, the number of layers of polymer 12 and the number of layers of the second material 14 shown in FIG. 9B are constant along the length of the plastic material 20, resulting in a uniform thickness of the plastic material 20. A plastic support of a desired shape and thickness may then be cut from the material shown. The plastic support can be in a shape of an underwire 11, a reinforcing pad 40, an uplifting panel 42, or a sternum region 17, as shown in FIG. 1. Additionally or optionally, the plastic support can be in a different shape of an uplifting panel 144, a reinforcing pad 140, a sternum region 142, or an extended fish bone like pattern 130 as shown in FIG. 12.

Optional, an adhesive can be used at the interface between each layer of polymer and the at least one layer of the second material, for causing said layers to adhere to each other so they maintain their relative position during further processing.

Optionally, the plastic support may comprise one or more layer of polymer 12 only, without layers of the second material 14. Second material 14 may be selected from the group of polymer, fabric and foam.

It is indeed a matter of choice to have the plastic material having either only layer(s) of polymer or combination of layer(s) of polymer together with layer(s) of fabric and/or foam, subject to the amount of support desired.

FIG. 10 shows a mold 15 in which a brassiere cup and plastic support in the form of underwire 11 are molded. The mold comprises a trough 16 defining the overall shape of the underwire 11. The trough 16 is deep at A and shallow at B. The desired layers of fabric and/or foam material are set down upon the mold 15 and extend into the trough. Plastics support of desired shape and thickness made of the plastic material 20 of FIG. 9A or FIG. 9B is then placed over the fabric and/or foam material which extends into the trough 16. The deep end of the trough 16 accepts more plastic material 20 than the shallow end. Either during or after the molding process in which other layers of foam and/or fabric material are pressed against the plastics material 20 to encase it, heat sufficient to melt/soften the plastics material 20 and pressure is applied so that the plastic material 20 melts into a continuous support of variable depth along its length and forms a whole piece of material together with the fabric and/or foam material.

FIG. 11 shows a different mold 15 in which a brassiere cup and plastic support in the form of underwire 11 are molded. The mold comprises a trough 16 defining the overall shape of the underwire 11. The trough 16 of uniform depth is wide at A and narrow at B. The desired layers of fabric and/or foam material are set down upon the mold 15 and extend into the trough. Plastic support of desired shape made of the plastics material 20 of FIG. 9A or FIG. 9B is then placed over the fabric and/or foam material which extends into the trough 16. The wide end of the trough 16 accepts more plastic material 20 than the narrow end. Either during or after the molding process in which other layers of foam and/or fabric material are pressed against the plastics material 20 to encase it, heat sufficient to melt/soften the plastics material 20 and pressure are applied so that the plastic material 20 melts into a continuous support of variable depth along its length and may form a whole piece of material together with the fabric and/or foam material.

Features 40, 42 and 17 shown in FIG. 1 are examples of other parts of a brassiere that can comprise reinforcing and support panels formed by practically the same method as described for manufacturing the underwire. These are areas of the brassiere that would typically require extra strength and provide additional support. For example, it might be desirable to incorporate a reinforcing pad behind typical hook and loop fasteners 40. This would enable the user to more positively secure the hook fasteners to the loop fasteners. At the sternum region 17 between the brassiere cups, extra reinforcing might be desired. Furthermore, special uplifting panels 42 could be provided at the outer edge regions of each cup. Each of these features might be provided by a mold having a cavity to receive granular plastics material to be heat-melded in a manner similar to that described. The uplifting panels 42 and sternum reinforcing area 17 could be made individually as a plastic support described above. Alternatively, the uplifting panels 42 and sternum reinforcing area 17 could be formed integrally with another plastic support as extensions thereof.

It should be appreciated that modifications and alterations obvious to those skilled in the art are not to be considered as beyond the scope of the present invention. For example, rather than using continuous fixed length supports of polymer/foam/fabric materials in the method of manufacturing the plastic support, continuous variable-length supports of polymer/foam material could be laid one upon another in stepwise manner such that thickness of the material varies along the plastic support. These layers could then be melded together upon the application of heat and pressure to remove any steps between the layers. Furthermore, different thickness of polymer can be used together or separately to form a plastic support. Even furthermore, two or more polymer layers can be used to form the plastic support, where at least two of the polymer layers are comprised of a different polymer, chosen from the group of a resin, a PVC (Poly Vinyl Chloride) or EVA (Ethylene Vinyl Acetate). Accordingly, it is intended that the present invention not be limited to the described embodiments, but that it has the full scope suggested by the above-language, as well as equivalents thereof. 

1. A brassiere cup plastic support comprising at least one layer of polymer and at least one layer of a second material; wherein the plastic support is in the shape of one or more of an underwire, an uplifting panel, a reinforcing pad, a sternum region, or an extended fish bone like pattern.
 2. The brassiere cup plastic support of claim 1, wherein the plastic support comprises at least two layers of the polymer and the at least one layer of the second material is formed sandwiched between the at least two layers of the polymer.
 3. The brassiere cup plastic support of claim 1, wherein the second material is selected from a group comprising a polymer, a fabric and a foam.
 4. The brassiere cup plastic support of claim 1, wherein the plastic support has a constant number of layers of the polymer and second material, so as to have a uniform crosswise dimension along its length.
 5. The brassiere cup plastic support of claim 1, wherein the plastic support has a variable number of layers of at least one of the polymer and second material along its length, so as to have a varied crosswise dimension along its length.
 6. The brassiere cup plastic support of claim 5, wherein the dimension graduates from a minimum at one end of the plastic support to a maximum at the other end of the plastic support.
 7. The brassiere cup plastic support of claim 1, wherein the polymer is selected from the group of an ethylene vinyl acetate (EVA), a resin, or a poly vinyl chloride (PVC).
 8. The brassiere cup plastic support of claim 1, wherein the plastic support is formed by cutting a desired shape from the plastic strip.
 9. The brassiere cup plastic support of claim 1, wherein the plastic support is formed by molding.
 10. The brassiere cup plastic support of claim 1, further including an adhesive material positioned at the interface between each layer of polymer and the at least one layer of the second material, for causing said layers to adhere to each other.
 11. The brassiere cup plastic support of claim 1 located in an edge region of a brassiere cup.
 12. The brassiere cup plastic support of claim 1 located between layers of material from which the brassiere cup is formed.
 13. A brassiere having a pair of the brassiere cups of claim
 1. 14. A method of manufacturing a brassiere part with a plastic support, comprising the steps of: (a) providing at least one layer of a polymer; (b) providing at least one layer of a second material on top of the layer of polymer; (c) applying an adhesive at the interface between the at least one layer of polymer and the at least one layer of the second material, for causing said layers to adhere to each other and form a layered plastic support; (d) cutting the plastic support from the layered plastic support, where the size and shape of the plastic support cut from the layered plastic support corresponds to a desired size and shape for the plastic support of the brassiere part after application of heat as noted by Step (h); (e) providing a mold for forming the brassiere part with a trough; (f) laying down in the mold a brassiere part material from which the brassiere part is to be formed, such that some of the brassiere part material extends into the trough; (g) positioning the plastic support cut from the layered plastic support upon the brassiere part material that extends into the trough; and (h) applying heat to the mold sufficient to soften the plastic support so that it consolidates into a desired shape as defined by the shape of the trough, melts into a continuous strip and forms a whole piece of material together with the brassiere part material.
 15. The method of claim 14 wherein step (b) provides the second material from a group comprising a foam, a fabric and a polymer.
 16. The method of claim 14 wherein the brassiere part is a cup and the plastic support is an underwire, and where during step (h) the plastic material consolidates in the trough to form the underwire so as to have either a variable or uniform width and/or depth from one end of the underwire to the other.
 17. The method of claim 14, wherein step (a) provides multiple layers of polymer.
 18. The method of claim 14, wherein steps (a) and (b) each provide multiple layers of their respective polymer and second material, until a plastic material of desired shape and thickness is complete.
 19. The method of claim 14, wherein step (f) provides further layers of material for laying down, from which the brassiere cup is to be formed, so as to cover the plastic material in the trough before step (h).
 20. The method of claim 14 wherein the brassiere part is a cup and the plastic support is in the shape of one or more of an uplifting panel, a reinforcing pad, a sternum region, or an extended fish bone like pattern. 